Conformal Source and Drain Contacts for Multi-Gate Field Effect Transistors

ABSTRACT

A semiconductor device includes a fin having a first semiconductor material, the fin having a source/drain (S/D) region and a channel region, the S/D region providing a top surface and two sidewall surfaces; an isolation structure surrounding a bottom portion of the fin, wherein the S/D region of the fin above the isolation structure has a step profile in each of the two sidewall surfaces; a semiconductor film over the S/D region and having a doped second semiconductor material, the semiconductor film providing a top surface and two sidewall surfaces over the top and two sidewall surfaces of the fin respectively, wherein the doped second semiconductor material is different from the first semiconductor material; and a metal contact over the top and two sidewall surfaces of the semiconductor film and operable to electrically communicate with the S/D region.

PRIORITY

This application is a continuation of U.S. patent application Ser. No.15/447,967 filed on Mar. 2, 2017 and issued as U.S. Pat. No. 10,164,033,which is a divisional of U.S. patent application Ser. No. 14/985,203filed Dec. 30, 2015, each of which is hereby incorporated by referencein its entirety.

BACKGROUND

The semiconductor integrated circuit (IC) industry has experiencedexponential growth. Technological advances in IC materials and designhave produced generations of ICs where each generation has smaller andmore complex circuits than the previous generation. In the course of ICevolution, functional density (i.e., the number of interconnecteddevices per chip area) has generally increased while geometry size(i.e., the smallest component (or line) that can be created using afabrication process) has decreased. This scaling down process generallyprovides benefits by increasing production efficiency and loweringassociated costs. Such scaling down has also increased the complexity ofprocessing and manufacturing ICs.

For example, multi-gate field effect transistors (FETs) such as finfield effect transistors (FinFETs) have been developed for better gatecontrollability than traditional planar FETs in short channeltransistors. Examples of the multi-gate FinFET include double-gate FET,triple-gate FFET, omega-gate FET, and gate-all-around (or surround-gate)FET. The multi-gate FETs are expected to scale the semiconductor processtechnology beyond the limitations of the conventional bulkmetal-oxide-semiconductor FET (MOSFET) technology. However, as thetransistor device structure scales down and becomes three dimensional,the transistor contact resistance exhibits increased impact on thedevice performance. Therefore, it is desirable to have new contactstructures that reduce the contact resistance.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure is best understood from the following detaileddescription when read with the accompanying figures. It is emphasizedthat, in accordance with the standard practice in the industry, variousfeatures are not drawn to scale and are used for illustration purposesonly. In fact, the dimensions of the various features may be arbitrarilyincreased or reduced for clarity of discussion.

FIGS. 1A and 1B are perspective and cross-sectional views of asemiconductor device constructed according to various aspects of thepresent disclosure.

FIG. 2 shows a flow chart of a method of fabricating the semiconductordevice of FIGS. 1A and 1B, according to some embodiments.

FIGS. 3, 4, 5, 6, 7A, 8, 9, and 10 are perspective views of forming asemiconductor device according to the method of FIG. 2, in accordancewith some embodiments. FIGS. 7B, 7C, and 7D are cross-sectional views ofthe semiconductor device of FIG. 7A, in accordance with someembodiments.

FIGS. 11, 12, 13, and 14 are cross-sectional views of forming asemiconductor device according to the method of FIG. 2, in accordancewith some embodiments.

DETAILED DESCRIPTION

The following disclosure provides many different embodiments, orexamples, for implementing different features of the provided subjectmatter. Specific examples of components and arrangements are describedbelow to simplify the present disclosure. These are, of course, merelyexamples and are not intended to be limiting. For example, the formationof a first feature over or on a second feature in the description thatfollows may include embodiments in which the first and second featuresare formed in direct contact, and may also include embodiments in whichadditional features may be formed between the first and second features,such that the first and second features may not be in direct contact. Inaddition, the present disclosure may repeat reference numerals and/orletters in the various examples. This repetition is for the purpose ofsimplicity and clarity and does not in itself dictate a relationshipbetween the various embodiments and/or configurations discussed.

Further, spatially relative terms, such as “beneath,” “below,” “lower,”“above,” “upper” and the like, may be used herein for ease ofdescription to describe one element or feature's relationship to anotherelement(s) or feature(s) as illustrated in the figures. The spatiallyrelative terms are intended to encompass different orientations of thedevice in use or operation in addition to the orientation depicted inthe figures. The apparatus may be otherwise oriented (rotated 90 degreesor at other orientations) and the spatially relative descriptors usedherein may likewise be interpreted accordingly.

The present disclosure is generally related to semiconductor devices,and more particularly to semiconductor devices having multi-gate FETsthat include conformal source and drain (S/D) contacts. Examples of themulti-gate FETs include double-gate FETs, triple-gate FETs, omega-gateFETs, and gate-all-around (GAA) FETs. Furthermore, the GAA FETs mayinclude one or more of the nanowire channel, the bar-shaped channel, orother suitable channel structures. An object of the present disclosureis to provide a novel S/D contact structure for the multi-gatetransistors so as to reduce the S/D contact resistance thereof. Inembodiments, an interface between an S/D contact and an underlyingsemiconductor fin has a substantially conformal profile with respect tothe shape of the underlying fin. In another word, the S/D contacteffectively covers at least a top surface and two sidewall surfaces ofthe underlying fin. Such structure provides increased interface areabetween the S/D contact and the underlying fin, thereby reducing the S/Dcontact resistance compared to the conventional S/D contacts.

FIGS. 1A and 1B show a semiconductor device 100 having such a conformalS/D contact structure, constructed according to various aspects of thepresent disclosure. Particularly, FIG. 1A is a perspective view of thedevice 100 and FIG. 1B is a cross-sectional view of the device 100 alongthe “1-1” line of FIG. 1A.

As shown, the device 100 is a multi-gate FinFET device. Furthermore, thedevice 100 may be an intermediate device fabricated during processing ofan integrated circuit (IC), or a portion thereof, that may comprisestatic random access memory (SRAM) and/or other logic circuits, passivecomponents such as resistors, capacitors, and inductors, and activecomponents such as p-type FETs, n-type FETs, metal-oxide semiconductorfield effect transistors (MOSFET), complementary metal-oxidesemiconductor (CMOS) transistors, bipolar transistors, high voltagetransistors, high frequency transistors, other memory cells, andcombinations thereof.

Referring to FIGS. 1A and 1B collectively, the device 100 includes asubstrate 102, an isolation structure 103 over the substrate 102, and aplurality of fins 104 projecting upwardly (along the “z” direction) fromthe substrate 102 and above the isolation structure 103. The device 100further includes a gate stack 110 and a gate spacer 112 on sidewalls ofthe gate stack 110. The gate stack 110 engages each of the fins 104 onthree sides thereof, forming multiple gating surfaces (hence the term“multi-gate” device 100). Although FIGS. 1A and 1B show six fins in thedevice 100, this is not limiting. In embodiments, the device 100 mayinclude one fin or any number of fins. The gate stack 110 engages therespective fins 104 at a channel region (not shown) of the device 100.The fins 104 further provide source and drain (S/D) regions of thedevice 100 on opposing sides of the gate stack 110. The device 100further includes S/D contacts 116 that are operable to electricallycommunicate with the S/D regions in the fins 104.

The device 100 further includes a plurality of semiconductor films 106.Each of the films 106 covers the S/D regions of a respective fin 104.The films 106 are substantially conformal to the shape of the fins 104.The term “substantially conformal” as used herein means that a topsurface of the films 106 is substantially parallel to a top surface ofthe fins 104, and sidewall surfaces of the films 106 are substantiallyparallel to sidewall surfaces of the fins 104. However, the thickness ofthe films 106 may or may not be uniform in various embodiments. In thepresent embodiment, the top surface of the films 106 and the top surfaceof the fins 104 are in the (100) crystal orientation (the “x-y” plane asillustrated), and the sidewall surfaces of the films 106 and the fins104 are in the (110) crystal orientation. In alternative embodiments,the aforementioned surfaces may be in other crystal orientations. Forexample, the sidewall surfaces of the films 106 and the fins 104 may bein the (551) crystal orientation in another embodiment. In the presentembodiment, the films 106 include a doped semiconductor material thatprovides a conductive path between the S/D contacts 116 and the S/Dregions of the fins 104.

In the present embodiment, the device 100 further includes a conductionlayer 108 between the S/D contacts 116 and the semiconductor films 106.In an embodiment, the conduction layer 108 is a metallization of aportion of the semiconductor films 106, such as by silicidation orgermanosilicidation. In another embodiment, the conduction layer 108 isan ultrathin dielectric layer that helps reduce Fermi-level pinningeffects between a metallic material (e.g., the S/D contacts 116) and asemiconductor material (e.g., the semiconductor films 106).

As can be seen in FIGS. 1A and 1B, the S/D contact structure of thedevice 100 includes multiple layers, one covering another with aninter-layer interface conforming to the shape of the fins 104. In thepresent embodiment, the semiconductor films 106 cover the respectivefins 104, the conduction layer 108 covers the semiconductor films 106,and the S/D contacts 116 cover the conduction layer 108. Such conformalcontact structure provides the maximum conducting interface area betweenthe S/D contacts 116 and the fins 104, thereby reducing the S/D contactresistance. More details about the device 100, including the materialsused for each of the features discussed above and the methods of formingthe same, are described below.

FIG. 2 shows a flow chart of a method 200 of forming a multi-gatesemiconductor device having conformal S/D contacts, such as thesemiconductor device 100, according to various aspects of the presentdisclosure. The method 200 is merely an example, and is not intended tolimit the present disclosure beyond what is explicitly recited in theclaims. Additional operations can be provided before, during, and afterthe method 200, and some operations described can be replaced,eliminated, or moved around for additional embodiments of the method.

At operation 202, the method 200 (FIG. 2) receives a device 100 as shownin FIG. 3. Referring to FIG. 3, the device 100 includes a substrate 102and a plurality of fins 104 projecting upwardly (along the “z”direction) from the substrate 102. The plurality of fins 104 areisolated by an isolation structure 103 that is disposed over thesubstrate 102.

The substrate 102 is a silicon substrate in the present embodiment.Alternatively, the substrate 102 may comprise another elementarysemiconductor, such as germanium; a compound semiconductor includingsilicon carbide, gallium arsenic, gallium phosphide, indium phosphide,indium arsenide, and/or indium antimonide; an alloy semiconductorincluding SiGe, GaAsP, AlInAs, AlGaAs, GalnAs, GaInP, and/or GaInAsP; orcombinations thereof.

The fins 104 may comprise at least a semiconductor material selectedfrom the group consisting of silicon, silicon-germanium(Si_(1-x)Ge_(x)), germanium, and III-V compound semiconductors such asgallium arsenide, indium gallium arsenide (In_(m)Ga_(1-m)As), indiumarsenide, indium phosphide, and indium antimonide. The fins 104 maycomprise strained Si_(1-x)Ge_(x) formed on Si, or strained Si formed onrelaxed silicon-germanium. In an embodiment, the fins 104 comprisestrained Si_(1-x)Ge_(x) and the substrate 102 comprises a relaxed orpartially relaxed silicon germanium alloy Si_(1-r)Ge_(r) layer, wherethe germanium mole fraction r is smaller than x. By selecting x to belarger than r, the natural lattice constant of the Si_(1-x)Ge_(x)channel is larger than that of Si_(1-r)Ge_(r), and the Si_(1-x)Ge_(x)channel is under compressive stress or strain. In embodiments, thecompressive strain in the channel in the longitudinal direction islarger than 0.5%, such as larger than 1%. In embodiments, the substrate102 may also comprise a silicon oxide (SiO₂) layer (i.e.silicon-on-insulator substrate), and the fins 104 may be formed from asilicon-on-insulator wafer.

Still referring to FIG. 3, although labeled on only one fin, each of thefins 104 (or simply the fin 104) includes two source/drain (S/D) regions104 a and a channel region 104 b between the two S/D regions 104 a. TheS/D regions 104 a and the channel region 104 b are arranged horizontallyalong the “y” direction. In the present embodiment, the fin 104 has arectangular or trapezoidal profile in the “x-z” plane.

The widths of the fin 104 at its top, central, and bottom (right abovethe isolation structure 103) portions along the “x” direction areW_(fin-top), W_(fin), and W_(fin-bottom) respectively. The fin 104 has aheight H_(fin) above the isolation structure 103 along the “z”direction. The plurality of fins 104 are spaced from each other alongthe “x” direction with a spacing S_(fin) and an edge-to-edge pitchP_(fin). In embodiments, the fin widths W_(fin-top) and W_(fin-bottom)may be 10 nanometers (nm) or smaller, such as 8 nm or smaller. Inembodiments, W_(fin-top) may be equal to or smaller than W_(fin) whichin turn may be equal to or smaller than W_(fin-bottom). In embodiments,the fin height H_(fin) may be equal to or greater than 30 nm, such as 40nm or greater, or even 50 nm or greater. In embodiments, the fin pitchP_(fin) may be 30 nm or smaller. In the present embodiment, the finsidewall surfaces are of (110) crystal orientation and the fin topsurface is of (100) crystal orientation. The fin sidewall surfaces maybe of other crystal orientations such as (551). Other configurations andshapes of the fins 104 are possible and are within the scope of thepresent disclosure.

In embodiments, where the fins 104 comprise Si fins and Si_(1-x)Ge_(x)fins, Si_(1-x)Ge_(x) fins may be formed together with Si fins andSi_(1-x)Ge_(x) fins may be adjacent to Si fins. Further, Si_(1-x)Ge_(x)fins and Si fins need not have the same physical dimensions of H_(fin),W_(fin-top), and W_(fin-bottom). The Si_(1-x)Ge_(x) fins may be used forp-channel transistors, while the Si fins may be used for n-channeltransistors. In embodiments, as the Si fins 104 are formed on a fully orpartially relaxed Si_(1-r)Ge_(r) layer in the substrate 102, the Si finswould be under tensile stress or strain in the longitudinal direction.The presence of tensile strain in the longitudinal direction increasesthe electron mobility in Si, and improves the drive current and speedperformance of the n-channel Si transistors.

The fins 104 may be fabricated using suitable processes includingphotolithography and etching processes. The photolithography process mayinclude forming a photoresist layer (resist) overlying the substrate102, exposing the resist to a pattern, performing post-exposure bakeprocesses, and developing the resist to form a masking element includingthe resist. The masking element is then used for etching recesses intothe substrate 102, leaving the fins 104 on the substrate 102. Theetching process can include dry etching, wet etching, reactive ionetching (RIE), and/or other suitable processes. Alternatively, the fins104 may be formed using mandrel-spacer double patterning lithography.Numerous other embodiments of methods to form the fins 104 may besuitable.

The isolation structure 103 may be formed of silicon oxide, siliconnitride, silicon oxynitride, fluoride-doped silicate glass (FSG), alow-k dielectric material, and/or other suitable insulating material.The isolation structure 103 may be shallow trench isolation (STI)features. In an embodiment, the isolation structures 103 is formed byetching trenches in the substrate 102, e.g., as part of the fins 104formation process. The trenches may then be filled with isolatingmaterial, followed by a chemical mechanical planarization (CMP) process.Other isolation structure such as field oxide, LOCal Oxidation ofSilicon (LOCOS), and/or other suitable structures are possible. Theisolation structure 103 may include a multi-layer structure, forexample, having one or more thermal oxide liner layers.

At operation 204, the method 200 (FIG. 2) forms a gate stack 110 a overthe fins 104, particularly, over the channel regions 104 b. In thepresent embodiment, the gate stack 110 a is a placeholder and will bereplaced by a final gate stack in a gate-last process. Therefore, thegate stack 110 a is also referred to as a dummy gate stack 110 a. Inalternative embodiments, the gate stack 110 a is the final gate stack,e.g., in a gate-first process. Referring to FIG. 4, the dummy gate stack110 a includes a dummy interfacial layer 120, a dummy gate electrode122, and a hard mask layer 124. The dummy interfacial layer 120 mayinclude a dielectric material such as silicon oxide layer (e.g., SiO₂)or silicon oxynitride (e.g., SiON), and may be formed by chemicaloxidation, thermal oxidation, atomic layer deposition (ALD), chemicalvapor deposition (CVD), and/or other suitable methods. The dummy gateelectrode 122 may include poly-crystalline silicon (poly-Si) and may beformed by suitable deposition processes such as low-pressure chemicalvapor deposition (LPCVD) and plasma-enhanced CVD (PECVD). The hard masklayer 124 may include one or more layers of material such as siliconoxide and/or silicon nitride. In embodiments, the dummy gate stack 110 amay include other suitable layers. The various layers of the dummy gatestack 110 a may be formed by photolithography and etching processes.

At operation 206, the method 200 (FIG. 2) forms a gate spacer 112 oversidewalls of the dummy gate stack 110 a. This may involve one or moredeposition and etching processes. In an embodiment, a spacer is formedon the sidewalls of both the dummy gate stack 110 a and the fins 104,and then it is removed from the sidewalls of the fins 104, leaving onlythe portion on the sidewalls of the dummy gate stack 110 a. This isillustrated in FIGS. 5 and 6.

Referring to FIG. 5, in an embodiment, a spacer material is deposited asa blanket over the isolation structure 103, the fins 104, and the dummygate stack 110 a. Then the spacer material is etched by an anisotropicetching process to expose the isolation structure 103, the hard masklayer 124, and a top surface 104′ of the fins 104. As a result, onlyportions of the spacer material on the sidewalls of the dummy gate stack110 a and the sidewalls of the fins 104 remain. The portion of thespacer material on the sidewalls of the dummy gate stack 110 a isreferred to as the gate spacer 112, while the portion of the spacermaterial on the sidewalls of the fins 104 is referred to as the finspacer 112 a. In embodiments, the spacer material may comprise adielectric material, such as silicon oxide, silicon nitride, siliconoxynitride, silicon carbide, other dielectric material, or combinationsthereof. Furthermore, the gate spacer 112 and the fin spacer 112 a maycomprise one or multiple layers of material.

Referring to FIG. 6, the fin spacer 112 a is substantially removed whilethe gate spacer 112 remains. In an embodiment, this is achieved by oneor more treatment and etching processes. In a first step of thisembodiment, the gate spacer 112 is selectively modified to have adifferent etch resistance than that of the fin spacer 112 a. Forexample, this can be done by a directional ion implantation (e.g. oxygenimplant) or plasma treatment in the presence of a directional ion beamso that the gate spacer 112 is more resistant to an etchant than the finspacer 112 a. In a second step of this embodiment, the fin spacer 112 ais substantially removed by a selective etching process while the gatespacer 112 substantially remains. As shown in FIG. 6, the etchingprocess exposes the sidewall surfaces 104″ of the fins 104. Also shownin FIG. 6, a small portion of the fin spacer 112 a remains at the feetof the fins 104. In alternative embodiments, the fin spacer 112 a may becompletely removed. In embodiments, operation 206 further includes acleaning process that cleans the surfaces of the fins 104 including thesurfaces 104′ and 104″ and prepares them for a subsequent epitaxialgrowth process. The various etching and cleaning processes above mayrecess the fins 104 slightly.

At operation 207, the method 200 (FIG. 2) trims the fins 104 in thesource and drain regions 104 a. The trimming increases the lateralspacing S_(fin) along the “x” direction, providing benefits forsubsequent fabrication stages. The device 100 post the operation 207 isshown in FIGS. 7A, 7B, 7C, and 7D collectively. FIG. 7B is across-sectional view of the trimmed source/drain regions 104 a along the“2-2” line of FIG. 7A. FIG. 7C is a cross-sectional view of the channelregion 104 b along the “3-3” line of FIG. 7A superimposed with thecross-sectional view of the source/drain regions 104 a of FIG. 7B. FIG.7D is a cross-sectional view of the fin 104 along the “4-4” line of FIG.7A. Referring to FIG. 7A, the fins 104 are trimmed to have a new centralwidth W_(fin2) that is smaller than W_(fin) (FIG. 3). In embodiments,the reduction in the fin width may be between 0.5 nm to 10 nm dependingon the width of the fins 104. In the present embodiment, the reductionin the fin width is about 5 nm or less, such as about 3 nm or less.Referring to FIG. 7B, the top and bottom widths of the fins 104 arereduced accordingly. The lateral spacing S_(fin) between two adjacentfins are thereby increased by (W_(fin)−W_(fin2)). This increase isdesirable for at least two reasons. First, it creates more room for thesubsequent epitaxial growth process. Without the trimming of the fins104, epitaxial growth off of the fins 104 might merge, resulting inreduced S/D contact area. Second, if there is not enough spacing betweenthe fins 104 after the subsequent epitaxial growth, it will be difficultfor depositing S/D contact material to fully wrap around the fins 104.The height of the fin H_(fin) may be reduced slightly by the trimmingprocess. The new top and sidewall surfaces of the fins 104 are stilllabeled as 104′ and 104″ (FIG. 7A) respectively for the sake ofconvenience. Since the channel regions 104 b are covered by the dummygate stack 110 a, they are not trimmed by this process. Referring toFIGS. 7C and 7D, as a result of the operation 207, the width of the S/Dregions 104 a (W_(fin2)) is now smaller than the width of the channelregions 104 b (W_(fin)) and the height of the S/D regions 104 a(H_(fin2)) is now smaller than the height (H_(fin)) of the channelregions 104 b. In embodiments, the operation 207 may include a wet etchin solution, reactive ion etch (RIE) in low density plasma, single-stepetch at cryogenic conditions in inductively coupled plasma (ICP)combined with RIE, time-multiplexed deep silicon etch in ICP-RIEconfiguration reactor, single-step etch in high density plasma at roomor near room temperature, or other etching methods suitable for thematerial of the fins 104.

At operation 208, the method 200 (FIG. 2) forms a doped semiconductorfilm (or films) 106 over the fins 104. Referring to FIG. 8, the film 106is formed to cover the S/D regions 104 a. Further, the film 106 has asubstantially conformal profile with respect to the fins 104, with itstop surface 106′ substantially parallel to the fin top surface 104′ andits sidewall surfaces 106″ substantially parallel to the fin sidewallsurface 104″. In an embodiment, each of the sidewall surfaces 106″ issubstantially perpendicular to the top surface 106′. In the presentembodiment, the sidewall surfaces 106″ do not meet the top surface 106′directly. Rather, they are connected through a respective intermediatesurface 106′″ of the film 106. In an alternative embodiment, thesidewall surfaces 106″ meet the top surface 106′ directly to form edgesthere between. In embodiments, the film 106 is about few nanometersthick, such as from about 1 nm to about 5 nm.

In embodiments, the film 106 is a heavily doped and epitaxially grownsemiconductor film. In some embodiments, the device 100 is a p-channelmulti-gate FET, the fins 104 includes Si or Si_(1-x)Ge_(x), and the film106 may be boron-doped Si_(1-y)Ge_(y), where y is equal to or largerthan x to induce longitudinal compressive strain in the channel for holemobility enhancement. In some embodiments, the device 100 is ann-channel multi-gate FET, the fins 104 includes Si, and the film 106 maybe phosphorus-doped silicon (Si:P) or phosphorus-doped silicon-carbon(Si_(1-z)C_(z)P). In embodiments, where the fins 104 include a compoundsemiconductor such as In_(m)Ga_(1-m)As, the doped epitaxial film 106 maybe In_(n)Ga_(1-n)As, where n is smaller than or equal to m. Inembodiments, where the device 100 includes both p-channel and n-channelFETs, the doped semiconductor films 106 may be formed separately in thep-channel and n-channel device regions. For example, an n-type film 106is formed first with the p-channel device regions covered by a hardmask, and then a p-type film 106 is formed with the n-channel deviceregions covered by a hard mask.

In an embodiment, the semiconductor film 106 is formed by one or moreselective epitaxy growth (SEG) processes. In one example, the SEGprocess is a low pressure chemical vapor deposition (LPCVD) processusing a silicon-based precursor gas. To further this embodiment, thegrowth of different facets of the semiconductor film 106 is controlledso as to achieve a desired profile as shown in FIG. 8. In the presentembodiment, the fin surfaces 104′ and 104″ are pre-processed to be inthe (100) and (110) crystal orientations, respectively. The growth ofthe semiconductor films 106 then follows the respective crystaldirection, i.e. growing in the [100] and [110] directions to form thetop surface 106′ and sidewall surfaces 106″. This results in the topsurface 106′ in the (100) facet, the sidewall surfaces 106″ in the (110)facet, and the intermediate surfaces 106′″ in the (111) facet. Invarious embodiments, the fin surfaces 104′ and 104″ are pre-processed tobe substantially of the (100) and (110) crystal orientations, i.e., theyare within ±10 degrees of the (100) and (110) crystal orientations,respectively. To further these embodiments, the epitaxial growth followsthe respective crystal direction of the fin surfaces and the resultingsemiconductor films 106 have the top surface 106′ substantially in the(100) facet, the sidewall surfaces 106″ substantially in the (110)facet, and the intermediate surfaces 106′″ substantially in the (111)facet. In a further embodiment, the growth of the semiconductor films106 are controlled so that there is enough spacing between the films 106on adjacent fins 104 for subsequent fabrication steps, such asdepositing a metal in between the films 106.

In embodiments, the operation 208 in-situ dopes the grown semiconductorwith an n-type dopant such as phosphorus, or arsenic, or combinationsthereof for forming the doped silicon film 106 for n-type devices. Inembodiments, the operation 208 in-situ dopes the grown semiconductorwith a p-type dopant such as boron or indium for forming the doped SiGefilm 106 for p-type devices. In embodiments, an optional thermaltreatment may be performed to enhance the dopant activation in the film106, e.g. using rapid thermal annealing (RTA), millisecond anneal (MSA)or spike anneal, laser annealing (LSA), or other annealing techniques.

At operation 210, the method 200 (FIG. 2) replaces the dummy gate stack110 a with a final gate stack 110 using a gate-last process (also calleda replacement gate process). However, when operation 204 forms a finalgate stack instead of a dummy gate stack, operation 210 may be bypassed.In embodiments, operation 210 involves multiple steps as discussed belowwith reference to FIGS. 9 and 10.

Referring to FIG. 9, in a first step, a dielectric material layer 114 isdeposited over the isolation structure 103, the film 106, and the dummygate stack 110 a. The dielectric material layer 114 is also referred toas inter-layer dielectric (ILD) layer 114. In embodiments, a contactetch stop layer (CESL) may be formed underneath the ILD layer 114. TheCESL may include silicon nitride, silicon oxynitride, silicon nitridewith oxygen (O) or carbon (C) elements, and/or other materials. In oneexample, the CESL includes silicon nitride (Si₃N₄) having an intrinsicstress with a magnitude of 1 GPa or higher. The intrinsic stress iscompressive for p-channel devices and tensile for n-channel devices. TheILD layer 114 may include materials such as tetraethylorthosilicate(TEOS) oxide, un-doped silicate glass, or doped silicon oxide such asborophosphosilicate glass (BPSG), fused silica glass (FSG),phosphosilicate glass (PSG), boron doped silicon glass (BSG), and/orother suitable dielectric materials. The ILD layer 114 may be depositedby a PECVD process or other suitable deposition technique. In anembodiment, the ILD layer 114 is formed by a flowable CVD (FCVD)process. The FCVD process includes depositing a flowable material (suchas a liquid compound) over the substrate 102 to fill various trenches,and converting the flowable material to a solid material by a suitabletechnique, such as thermal annealing or ultra-violet radiation. The ILDlayer 114 is then etched back or planarized by a CMP process to exposethe hard mask layer 124.

Referring to FIG. 10, in a second step, the hard mask layer 124, thedummy electrode 122, and the dummy interfacial layer 120 are removed inone or more etching processes, thereby forming a recess between twosidewalls of the gate spacer 112. The various layers may be removed witha suitable wet etch, dry (plasma) etch, and/or other processes.Subsequently, one or more material layers are deposited into the recessto form the final gate stack 110. In one example, the gate stack 110includes an interfacial layer, a gate dielectric layer, a work functionmetal layer, and a metal fill layer. The interfacial layer may include adielectric material such as silicon oxide layer (SiO₂) or siliconoxynitride (SiON), and may be formed by chemical oxidation, thermaloxidation, atomic layer deposition (ALD), CVD, and/or other suitabledielectric. The interfacial layer is less than 1 nm thick in variousembodiments. The gate dielectric layer may include a high-k dielectriclayer such as hafnium oxide (HfO₂), zirconium oxide (ZrO₂), lanthanumoxide (La₂O₃), titanium oxide (TiO₂), yttrium oxide (Y₂O₃), strontiumtitanate (SrTiO₃), other suitable metal-oxides, or combinations thereof.The gate dielectric layer may be formed by ALD and/or other suitablemethods and may have a thickness ranging from about 1.0 nm to about 10nm. The work function metal layer may be a p-type or an n-type workfunction layer. The p-type work function layer comprises a metal with asufficiently large effective work function, selected from but notrestricted to the group of titanium nitride (TiN), tantalum nitride(TaN), ruthenium (Ru), molybdenum (Mo), tungsten (W), platinum (Pt), orcombinations thereof. The n-type work function layer comprises a metalwith sufficiently low effective work function, selected from but notrestricted to the group of titanium (Ti), aluminum (Al), tantalumcarbide (TaC), tantalum carbide nitride (TaCN), tantalum silicon nitride(TaSiN), or combinations thereof. The work function metal layer mayinclude a plurality of layers and may be deposited by CVD, PVD, and/orother suitable process. The metal fill layer may include aluminum (Al),tungsten (W), cobalt (Co), copper (Cu), and/or other suitable materials.The metal fill layer may be formed by CVD, PVD, plating, and/or othersuitable processes.

At operation 212, the method 200 (FIG. 2) forms contact holes 130 in theS/D regions to expose a portion of the top and sidewall surfaces of thefilm 106. This is illustrated in FIGS. 11 and 12, which arecross-sectional views of the device 100 along the “2-2” line of FIG. 10,showing the device 100 before and after the contact holes 130 areformed, respectively. In embodiments, the contact holes 130 are formedby one or more photolithography and etching processes. Thephotolithography process may form a hard mask over the device 100,having openings through which the contact holes 130 are etched. Theetching process may include a suitable wet etch, dry (plasma) etch,and/or other processes. For example, a dry etching process may usechlorine-containing gases, fluorine-containing gases, other etchinggases, or a combination thereof. The wet etching solutions may includeNH₄OH, HF (hydrofluoric acid) or diluted HF, deionized water, TMAH(tetramethylammonium hydroxide), other suitable wet etching solutions,or combinations thereof. As shown in FIG. 12, the contact holes 130expose a portion of the top surfaces 106′ and the sidewall surfaces 106″of the films 106.

At operation 214, the method 200 (FIG. 2) forms a conduction layer 108over the semiconductor film 106. Referring to FIG. 13, the conductionlayer 108 is conformal to the film 106 and the fin 104. In anembodiment, the conduction layer 108 is a metallization of a portion ofthe semiconductor film 106, such as by silicidation orgermanosilicidation. Silicidation or germanosilicidation generallyinvolves depositing a metal film, performing an annealing process, andremoving excess unreacted metal. For example, the metal film may have athickness of about 5 nm or less, such as 2 nm or less. In embodiments,the same metal film may be used for metallization of both n-type andp-type S/D regions. Alternatively, the metal material used formetallization of the n-type S/D regions may be different from the metalmaterial used for metallization of the p-type S/D regions. Inembodiments, the metal film includes titanium (Ti), nickel (Ni), cobalt(Co), tantalum (Ta), erbium (Er), yttrium (Y), ytterbium (Yb), platinum(Pt), or combinations thereof.

In another embodiment, the conduction layer 108 is an ultrathindielectric layer that helps reduce Fermi-level pinning effects between ametallic material (e.g., the S/D contacts 116 of FIG. 1A) and asemiconductor material (e.g., the semiconductor films 106). Theultrathin dielectric layer may be deposited by atomic layer deposition(ALD). In embodiments, where the conduction layer 108 is formed overn-type S/D regions, the dielectric material may be titanium oxide(TiO₂), tantalum oxide (Ta₂O₅), or any other dielectrics with a small ornegligible conduction band offset ΔE_(c) with respect to thesemiconductor material in the film 106 and the fin 104. In embodiments,the thickness of the dielectric conduction layer 108 is 1 nm or thinner,such as 0.5 nm or thinner. The small or negligible ΔE_(c) as well as theselection of an ultrathin thickness for the conduction layer 108 allowsa high current density to flow across without a large voltage drop.

In embodiments, the conduction layer 108 is formed over the film 106before the ILD layer 114 and the contact hole 130 are formed. In suchembodiments, the conduction layer 108 fully covers the film 106 in theS/D regions of the device 100. In the present embodiment, the conductionlayer 108 is formed over the film 106 after the contact holes 130 areformed. In such embodiments, the conduction layer 108 only covers theportion of the film 106 exposed by the contact holes 130.

At operation 216, the method 200 (FIG. 2) forms S/D contacts 116 bydepositing a metal in the contact holes 130. Referring to FIG. 14, theS/D contacts 116 fill the contact holes 130 and cover the fins 104through the conformal conduction layer 108 and the film 106. Inembodiments, the S/D contacts 116 comprise a metal with a work functionof 4.3 eV or lower. In embodiments, the S/D contacts 116 may comprisetungsten (W), cobalt (Co), copper (Cu), other elemental metals, metalnitrides such as titanium nitride (TiN), titanium aluminum nitride(TiAlN), tungsten nitride (WN), tantalum nitride (TaN), or combinationsthereof, and may be formed by CVD, PVD, plating, and/or other suitableprocesses. A CMP process may be performed to planarize a top surface ofthe device 100 to obtain the structure as shown in FIGS. 1A and 1B.

At operation 218, the method 200 (FIG. 2) performs further steps tocomplete the fabrication of the device 100. For example, operation 218may form a gate contact electrically connecting the gate stack 110, andmay form metal interconnects connecting the multi-gate FET to otherportions of the device 100 to form a complete IC.

Although not intended to be limiting, one or more embodiments of thepresent disclosure provide many benefits to a semiconductor device andthe formation thereof. For example, source/drain (S/D) contacts of thepresent disclosure provide larger contact areas to S/D regions of atransistor than conventional S/D contacts. The S/D contacts of thepresent disclosure provide a conformal contact interface that coversmultiple surfaces of the S/D regions, including a top surface and twosidewall surfaces thereof. The larger contact areas contribute to lowerS/D contact resistance.

In one exemplary aspect, the present disclosure is directed to asemiconductor device. The semiconductor device includes a fin having afirst semiconductor material. The fin includes a source/drain (S/D)region and a channel region. The S/D region provides a top surface andtwo sidewall surfaces. A width of the S/D region is smaller than a widthof the channel region. The semiconductor device further includes asemiconductor film over the S/D region and having a doped secondsemiconductor material. The semiconductor film provides a top surfaceand two sidewall surfaces that are substantially parallel to the top andtwo sidewall surfaces of the S/D region respectively. The semiconductordevice further includes a metal contact over the top and two sidewallsurfaces of the semiconductor film and operable to electricallycommunicate with the S/D region.

In another exemplary aspect, the present disclosure is directed to amethod of forming a field effect transistor (FET). The method includesproviding a fin, wherein the fin includes a first semiconductor materialand has a source region, a channel region, and a drain region for theFET. The method further includes forming a gate stack over the channelregion and trimming the fin to reduce a width of the fin in the sourceand drain regions. The method further includes forming a semiconductorfilm over the source and drain regions, wherein the semiconductor filmincludes a doped second semiconductor material and is substantiallyconformal to the fin. The method further includes depositing a metalover the semiconductor film, wherein the metal is operable toelectrically communicate with the source and drain regions.

In another exemplary aspect, the present disclosure is directed to amethod of forming a field effect transistor (FET). The method includesproviding a fin, wherein the fin includes a first semiconductor materialand has a source region, a channel region, and a drain region for theFET. The method further includes forming a dummy gate stack over thechannel region and forming a gate spacer over sidewalls of the dummygate stack. The method further includes trimming the fin to reduce awidth of the fin in the source and drain regions. The method furtherincludes forming a semiconductor film over the source and drain regions,wherein the semiconductor film includes a doped second semiconductormaterial and is substantially conformal to the fin. The method furtherincludes performing a replacement gate process thereby replacing thedummy gate stack with a metal gate. The method further includes formingcontact holes to expose a top surface and two sidewall surfaces of thesemiconductor film and depositing a metal in the contact holes.

The foregoing outlines features of several embodiments so that those ofordinary skill in the art may better understand the aspects of thepresent disclosure. Those of ordinary skill in the art should appreciatethat they may readily use the present disclosure as a basis fordesigning or modifying other processes and structures for carrying outthe same purposes and/or achieving the same advantages of theembodiments introduced herein. Those of ordinary skill in the art shouldalso realize that such equivalent constructions do not depart from thespirit and scope of the present disclosure, and that they may makevarious changes, substitutions, and alterations herein without departingfrom the spirit and scope of the present disclosure.

What is claimed is:
 1. A semiconductor device, comprising: a fin havinga first semiconductor material, the fin having a source/drain (S/D)region and a channel region, the S/D region providing a top surface andtwo sidewall surfaces; an isolation structure surrounding a bottomportion of the fin, wherein the S/D region of the fin above theisolation structure has a step profile in each of the two sidewallsurfaces; a semiconductor film over the S/D region and having a dopedsecond semiconductor material, the semiconductor film providing a topsurface and two sidewall surfaces over the top and two sidewall surfacesof the fin respectively, wherein the doped second semiconductor materialis different from the first semiconductor material; and a metal contactover the top and two sidewall surfaces of the semiconductor film andoperable to electrically communicate with the S/D region.
 2. Thesemiconductor device of claim 1, further comprising a conductive layerbetween the semiconductor film and the metal contact.
 3. Thesemiconductor device of claim 2, wherein the conductive layer is ametallization of the doped second semiconductor material.
 4. Thesemiconductor device of claim 1, further comprising a dielectric layerbetween the semiconductor film and the metal contact.
 5. Thesemiconductor device of claim 4, wherein the dielectric layer isoperable to reduce Fermi-level pinning effects between the semiconductorfilm and the metal contact.
 6. The semiconductor device of claim 1,wherein each of the two sidewall surfaces of the semiconductor film isconnected to the top surface of the semiconductor film through anintermediate surface of the semiconductor film.
 7. The semiconductordevice of claim 6, wherein the intermediate surface is substantially ofa (111) crystal orientation.
 8. The semiconductor device of claim 1,wherein the top surface of the semiconductor film is substantially of a(100) crystal orientation and each of the two sidewall surfaces of thesemiconductor film is substantially of a (110) crystal orientation. 9.The semiconductor device of claim 1, wherein the top surface of thesemiconductor film is substantially of a (100) crystal orientation andeach of the two sidewall surfaces of the semiconductor film issubstantially of a (551) crystal orientation.
 10. The semiconductordevice of claim 1, wherein the first semiconductor material comprisessilicon and the doped second semiconductor material comprisesphosphorus-doped silicon (Si:P) or phosphorus-doped silicon-carbon(Si_(1-z)C_(z):P).
 11. The semiconductor device of claim 1, wherein thefirst semiconductor material comprises In_(m)Ga_(1-m)As, and the dopedsecond semiconductor material comprises In_(n)Ga_(1-n)As, where n issmaller than or equal to m.
 12. A semiconductor device, comprising: afin having a first semiconductor material, the fin having a source/drain(S/D) region and a channel region, the S/D region providing a topsurface and two sidewall surfaces, wherein a lower portion of the fin isembedded in an isolation structure, and the S/D region of the fin abovethe isolation structure has a width smaller than the lower portion ofthe fin; a semiconductor film over the S/D region and having a dopedsecond semiconductor material, the semiconductor film providing a topsurface and two sidewall surfaces over the top and two sidewall surfacesof the fin respectively, wherein the doped second semiconductor materialis different from the first semiconductor material; and a metal contactover the top and two sidewall surfaces of the semiconductor film andoperable to electrically communicate with the S/D region.
 13. Thesemiconductor device of claim 12, wherein a height of the S/D region issmaller than a height of the channel region.
 14. The semiconductordevice of claim 12, wherein the width of the S/D region is smaller thana width of the channel region.
 15. The semiconductor device of claim 14,wherein the width of the S/D region is smaller than the width of thechannel region by 0.5 nm to 10 nm.
 16. The semiconductor device of claim12, further comprising a conductive layer between the semiconductor filmand the metal contact, wherein the conductive layer is a silicidation orgermanosilicidation of the doped second semiconductor material.
 17. Thesemiconductor device of claim 12, further comprising a dielectric layerbetween the semiconductor film and the metal contact, wherein thedielectric layer is operable to reduce Fermi-level pinning effectsbetween the semiconductor film and the metal contact.
 18. Asemiconductor device, comprising: a fin having a first semiconductormaterial, the fin having a source/drain (S/D) region and a channelregion, the S/D region providing a top surface and two sidewallsurfaces; an isolation feature surrounding a bottom portion of the fin;a semiconductor film over the S/D region and having a doped secondsemiconductor material, the semiconductor film providing a top surfaceand two sidewall surfaces over the top and two sidewall surfaces of thefin respectively, wherein the doped second semiconductor material isdifferent from the first semiconductor material, wherein thesemiconductor film is over the isolation feature; a conduction layerover the semiconductor film, the conduction layer providing a topsurface and two sidewall surfaces over the top and two sidewall surfacesof the semiconductor film respectively, wherein the conduction layer isspaced from the isolation feature by the semiconductor film; and a metalcontact over the top and two sidewall surfaces of the conduction layerand operable to electrically communicate with the S/D region.
 19. Thesemiconductor device of claim 18, wherein the conduction layer comprisesa metallization of the doped second semiconductor material.
 20. Thesemiconductor device of claim 18, wherein the conduction layer comprisesa dielectric material operable to reduce Fermi-level pinning effectsbetween the semiconductor film and the metal contact.